Insulated electrical conductors



1956 A. RHEINER ETAL INSULATED ELECTRICAL CONDUCTORS Filed Jan. 24, 1952 2 Sheets-Sheet 1 FIG.

FIG. In

FIG. 20

INVEN-TORSI ALFRED RHEINER 8- ATTORNEYS 21, 1956 A. RHEINER EIAL 7 2,759,991

INSULATED ELECTRICAL CONDUCTORS Filed Jan. 24, 1952 2 Sheets-Sheet 2 rub ber FIG. 6

TABLE OF LEGENDS .lconductors 2- cellulose acetate fiber insulation Bl- Cotopa or Isocel string 3- Isocel tape (of high porosity) Isocel tape covering the starquads 3- tnermoplastic sheath consisting f:

50- intermediate hygroscopic layer of cable paper 5l-inner thermoplastic sheath 32- outer thermoplastic sheath 33- third 'and outer thermoplastic sheath INVENTORSI ALFRED RHEINER 8r WALTER DIETERLE,

- ATTORNEYS portion, ofair-tspace in, the latter.

United States Patent O 2,759,991 INSULATED ELECTRICAL CONDUCTORS Alfred Rheiner and Walter Dieterle,! Basel, Switzerland, assignors to Sandoz A. G.-, -.Basel, Switzerlanit a Swiss firm Application January 24; 1952, SeriaLNo. 267,956 Claims priority, application switzerland tlanuary 26, 1951 3 Claims. (Cl. 174-420) The present invention relates to insulated electrical constructions (cables and the like) comprising essentially a cable core consisting of one or more insulated conductors, and a covering of thermoplastic, material.

It is a primary object of the present invention to embody insulated electrical conductors wherein, due inter alia to the character of the insulation employed, the structure is endowed with increased insulationlife, improved power or dissipation factor, 'improvedinsulation resistance characteristics, greater heat resistance, enhanced moisture resistance, reduced dielectric losses particularly at higher frequencies, smaller capacitydueyto smaller dielectric constant, anda general improvement of the constancy of these electric characteristics OI1"X- posure to varyinghumidity influences relative tothe corresponding;characteristics of the conventional paper electrical insulation.

This and other objects and advantages are realized by the constructions according to the present disclosure. These constructions, are especially. suitable for,,-weak-current (telephone) cables as well as forshigh voltage (in tense current) cables-and;highgtrequency transmission cables (carrier; cables).

It is a primary-characteristicof the structures according to this invention that the insulation consistmpartly or wholly of cellulose acetate-fibers. tWhere the insulation consists only partlyof the v,said fibers,- the remainder is constituted ;by air and/ona suitable ,impregnant of plastic or resinous material as ;hereinafter described. The term cellulose acetateifibersW-is intendejdgto designate materials which are obtained according ,to any fofithe known processes by acetylating cellulose fibers such as cotton, paper and regenerated cellulose with theretention of the fiber structure. It is advantageous to use products with a degree of acetylation of 26 to 62% by Weight of chemically combined acetic acid. example, Patent No."2,357,962.

Improved electrical performance, with respect to the hereinbefore-enumerated electrical, characteristics sof the insulation, ,is obtained by ;modifying the porositypfithe fibrous cellulose acetate insulation to increase the,.pr o- ,Tojhiscud, usenmay acetate, paper, ,woven a vanta o l ade r rou I cellulose acetate. .lt

fibrous cellulose acetate and fibrous is in-,th is, event, and in order-to compensate fora-any loss in, mechanical strengthwhich maybeibound y-with this porosity, that the insulation may; contain ,thesplastic or resinous impregnant precedin gly mentioned. Loss in mechan ca s ren t h ract ri ti s, ...a es l y in en es eng h, m y-becou t balance n mp egnatin theporouscellulose acetate materialwitha suitable, plastic ndlor es w ie mai tai the esir tnor ytb strengthens the material. Particularly,suitableirnpreg- See also, for

nants or coating agents for such reinforcement are: cellulosic derivatives such as acetylcellulose, monomeric or low, polymeric and polymerizable"thermoplasticsubstances such aslstyrene, polystyrene and itheir polymerizable derivativesawhich may be :catalytically polymerized in situ on the :material of the; insulation, thermoplastic polymers such! as polyethylene, thermosetting resins in p-recondensed or condensed state such as melamine-aldehyde resins and the modified: melamine-aldehyde resins, polyesters and 'silicones.

I'The amountz of resin impregnant which is applied to the cellulose acetate fabric base is quite small (of the order of about one to ten percent by weight) and is "therefore practically of' nosignificance with regard to the. electrical. performance" characteristics. ofthe insulation according to the invention. On' the other hand, in addition to improving themechanical.Icharacteristics, the I added irnpregnantt-may function toretard the absorption of moisturewhereby'the life'of'the cable may be still further increased.

"The advantage; of "the cables, according tothe present invention, comparedwith a cable whose insulation consists of ordinary paper, is thattheyishow a considerably increasedalife andbetter electrical, properties, and in comparison" with a cable 'made'with an artificial resin insulation, "they'possess better electrical properties and a; greater resistance to, heat. 'The last'named property proves of particular advantage'when the cable covering \1 issprayed on. *By electrical properties are meant inter alia" the resistance of the insulation, 'the power factor and the capacity of the 'insulation;'-andby increased life the increased stability of the insulation towards "moisture. The last mentioned property is of special significance because coveringsim-ade from- =therrnoplastic materials are permeable to moisture. EThfollowing example indicates the measure of theistability of fibercellulose .acetatestowards-"moisture-"in compari'son with those of non-acetylated cellulose:

Celluloseacetate fibers which contain by weight 40 of combined acetic acid and 'whichhave been. conditioned 1 at an 80% relative humidity show an insulation resistance 10 to 10 times greater and a power factor-25 times smaller than v.the corresponding non-acetylated material y conditioned,attf80%.relativehumidity. Furthermore, it I 1 exhibits a dielectric constant which only amounts to o to 90% of that of the non-acetylated material.

.The alteration of the electric dataunder theinfiuence tzof difiu'sing humidity of ax-cable With/thermoplastic cover insulated with cellulose, acetate fibers is'lsloweddown many times compared to a cablesmade'with the' usual *papefiinsulation; andi-ten'ds to ,-aconstant' Value $0 that a multiple of the life achieved so far (and recognized as insuflicient) is.obtained. vandsthus also a useful cable.

. Furthermore, a cable insulated .in this manner -.-distinguishes itself, as already mentioned, by betterelec- .trical properties, above-.allbecause- .of smaller-leakance, smaller .capaCiIYand, smallermdielectric losses.

.The ,above .mentionedbehaviorof the (paper :insulations flusedhithertotand of. an. insulationnaecording to the present invention made vfrom :cellulose --acetate fibers which contain 35% by weight of combined acetic acid towards .the influence .of .ditlusing. moisture is demon- .strated by measurements under various conditions.

.The following electrical measurements were carried out with cable-simulating :structures in the form of condensers which were tightly packed insuitable thermoplastic foils (polyethylene 0.05 mm.):

Cable covering or its equivalent Insulation Resistance Dielectric power factor in M12 tangens 6X10 Conditioning, Temperature, Time, Inter- C. and Days Ordinary Acetylated Outer mediate Inner Layer humidity Ordinary Acetylatcd cable paper, cable Layer Layer cablepaper cable paper 10 H2 pt plein 0 10 10 4.0 29 Plate Condenser. 1 23,000 250,000 9. 3 4. 4 20 C 4 122 170,000 67.0 7.5 (1) 1XPE0.05rnm 80% relative 20 l. 5 37,000 465.0 11-2 humidity. 100 0. 9 12,000 550 l3. 6

230 310,000 10 6.0 4.6 After drying 24 hours at 60 C. 43 hours over P205.

0 10 10 3.65 4.0 Plate Condenser. 1 1,000 10 11.6 4.0 a C 14 4. 3 500,080 23.0 0 0.3 200,0 0 -60 (2) 1XPE {in water 20 -41 3, 550 7.0

230 800,000 10 6 4 4.5 After drying 24 hours at 60 C. 48 hours over P205.

10 M9 denotes: highest insulation resistance measurable with the apparatus at hand, i. a. 210 Mil.

Plate condenser: 100 mm. 05, approx. 1 mm. thickness of the dielectric.

PE: Polyethylene. 1 According to the present invention. 1 Hz=cycles per second.

The measurements were made according to ASTM especially for insulation resistance: ASTM D 257-46 and for power factor and dielectric constant:

ASTM D 150-47 '1. [App.: Bridge General Radio 716-0.].

A further improvement to attain a. moisture-resistant, longer-lived insulation (and cable) of constant electrical properties is achieved by providing the cellulose acetate fibrous insulation (resin-impregnated or not) about the conductor with a laminated covering comprising an intermediate hygroscopic layer interposed between two thermoplastic or thermosetting moisture-resistant resinous layers. The intermediate hygroscopic layerregenerated cellulose, paper, cotton or the likeoperates to trap inwardly The behavior described, especially the inhibiting influence of the intermediate layer towards diffusion, is demonstrated by the following results of electrical measurements on cable-simulating structures in the form of condensers (insulation each time of ordinary cable paper and of acetylated cable paper containing 35% by weight of combined acetic acid, which were tightly Wrapped in two polyethylene foils of 0.05 mm. thickness each, in one case with an intermediate layer of cotton or paper):

Cable covering or its equivalent Insulation Resis- Dielectric power factor tangens tance in MSI 6x10 Conditioning, Tem- Time, perature, Days Ordi- Acety- Ordinary Acetylated Outer Intermediate Inner 0 C. and nary lated cable paper cable paper 1 Layer Layer Layer humidity cable cable paper paper 1 10Hz 2 10Hz 2 10Hz 2 10 112 1 0 10 10 4. 4 4. 65 1. 5. 0 Plate Condenser. -5 5 3 6 P3 525% ist 1%?) it (3) 1 PE 1 E 6 Q Over water" 11 550 550 21.3 19. 5 0:05 19 -41 2. 5 550 550 215. 0 28.5 25 -0 0. 5 550 550 400 0 10 10 3. 4 5. 3 1. 65 4. 3 Plate Condenser. 0 5 40 "3 255 62% 3'? ti 4 00 4 lXPE lXcotton, IXPE 6 over water" 11 0. 05 196 550 255.0 36. 0 11. 0 0.05 mm. aprgrpx. 40 0.05 mm. 19 N0 42 550 550 70. 5 15. 0 g 25 -0 42 550 550 58.0 13. 0

10 MSZ denotes: highest insulation rmistance measurable with the apparatus at hand, i. 0. 210 M9.

Plate condenser: mm. approx. 1 mm. thickness of the dielectric.

The measurements were made according to ASTM especially for insulation resistance: ASTM D 257-46 and for power factor and dielectric constant:

ASTM D -47 T. [App.: Bridge General Radio 716-0.]

diffusing moisture and thereby prevents its penetration to the insulation surrounding the conductor at the core of the cable.

A repeated structural series of such intermediate layer assembliesi. e. where each assembly is constituted by an intermediate layer, chosen to be as hygroscopic as possible, is inserted each time between two thermoplastic layers-makes it possible to realize a further considerable reduction of the diffusion of moisture towards the cable core, and the life of such a cable is thus still further prolonged. Normally two or three such assemblies will sufiicie. In certain applications a greater number may be desired, and no upper limit is placed on the number of such assemblies except as considerations of practicality are involved.

The accompanying drawings illustrate representative constructional embodiments in accordance with the invention.

Fig. 1a, and each of Figs. lb, 1c and id is a cross section through an insulated structure according to the invention;

Figs. 2a, 3a, 4a and 5a are cross-sectional showings of further embodiments of conductors, cables or the like according to the invention.

Fig. 6 is a table of explanatary legends.

Fig. 1a shows the fundamental relationship of parts according to the invention, 1 designating the c0nductor(s), 2 designating the cellulose acetate fiber insulation(s) therearound, and 3 designating the covering (shown here as a single thermoplastic layer).

parts (designated by reference characters 1, 2 and 3) occurs in all the subsequent figures of drawing.

Fig. 2a shows a laminated assembly 3 around the same cable core as that of Fig. la, said assembly consisting as hereinbefore described of a hygroscopic element 30 interposed between thermoplastic layers 31 and 32.

The structure according to Fig. 3a incorporates that according to Fig. 2a but additionally includes a third, outer thermoplastic layer 33.

The intermediate layer or layers 30 of hygroscopic material is selected so as to have as high a hygroscopicity as practical and to be of high density (which may be achieved by calendering). A well-suited material for this purpose, whose application in a similar sense (wrapping in the form of tapes or strips) is already known in the manufacturing of cables, is for example ordinary insulation paper which has however been as highly compressed as possible and which may, under certain circumstances, receive special treatment, for instance impregnation with a hygroscopic material such as silica gel, in order to increase its hygroscopicity. In the place of paper, compressed and/ or treated fabrics, e. g. cotton tapes, may be used with equal advantage.

In the construction according to Fig. 4a, which otherwise is identical with that of Fig. 2a, a metallic layer is inserted between the insulated core and the laminated covering. The metal, advantageously in foil form, may be of lead, aluminum, ferrous metal or the like. The metal insert may, sembly.

Fig. 5a illustrates an embodiment wherein the interior of the cable may correspond to any one of the embodiments of Figs. 1a to 4a, together with an exterior covering of material, such as rubber or the like, which is conventionally employed in cable structures. The outermost cover may however consist of any thermoplastic material of the required mechanical qualities-(primary emphasis being laid upon good resistance to abrasion and rubbing), and the inner coverings may take over the functions of protecting against moisture.

Thermoplastic resinous layers are preferred as the laminae between which the intermediate hygroscopic layer or layers are inserted, because the manufacture of the cable constructions is thereby readily adapted to conventional laminating operations and or to the use of a heated die under pressure, care being taken to maintain the water-retaining properties of the said intermediate layers.

Fig. 1b discloses a construction according to the invention wherein the core comprises a plurality of electrical conductors 1, three being shown in the illustrated embodiment. Each conductor is covered by a covering of cellulose acetate fiber insulation according to the invention, and the three conductors are arranged as shown to constitute a core of essentially circular cross section. This core is then sheathed in an outer thermoplastic sheath constituted by two layers 3.

Fig. 1c shows the starquad type of construction for the core of the cable, the starquads being encompassed by Isocel tape coverings 22, 23. The thus-constructed core is then sheathed in an outer sheathing 3 of thermoplastic material.

Fig. id is an enlarged detail of one of the starquads of Fig. 1c, and shows the conductors 1 associated with Cotopa or Isocel string 21, each group being wound with Isocel tape 22 of high porosity and the whole being enclosed in Isocel tape 23.

Example I In the following the construction of a telephone cable with 500 pairs of usual assembly of the pairs forming a core of approx. 60 mm. diameter may be described.

Core 0] the cable-The insulation of the conductors is of the well known air space paper cable type; however the strings wound round the bare copper wires consist of same relationship of if desired, occur within the laminated as- I acetylated cellulose fibers in paper form containing 35% by weight of combined acetic acid.

A spirally wound covering also consisting of acetylated cellulosic fibers in paper form is then placed around each single conductor with its air space string. This covering is applied in tapes and overlapping spirals.

The twisting and stranding of the pairs, quads and bundles is done as usual but for replacing the conventional insulating material by acetylated cellulosic fibres in paper form for taping the pairs, quads and bundles.

For terminating a tape of acetylated cotton with 30% combined acetic acid is tightly wound in overlapping spirals around the core.

Sheath of the c0re.-The core insulated as aforedescribed is taped with spirally wound and overlapping aluminium foil. Upon this aluminium foil layer a seamless tubular sheath of polyethylene is extruded. The cable so protected may be further provided with stuffing, armouring and bituminous serving.

Example 2 Description of a special cable for carrier telephony of the star quad type with 24 pairs or 12 spiral four quads with copper conductor of 1,3 mm. diameter. The assembly can be done according to the designs and methods applied so far for paper-type cables.

Core of the cable.-The insulation of the conductors is of the air space type, the strings wound spirally around the bare copper conductors consisting of acetylated cotton containng 62% by weight of combined acetic acid.

On these conductors served with these air space strings, a spirally wound paper tape of high porosity (density: 0.2-0.3 grammes per cmfi), consisting of acetylated cellulosic fibers with 35 combined acetic acid is applied. This highly porous acetylated paper-tape has previously been impregnated with 4-6% of its Weight of cellulose triacetate for improving its mechanical properties. For the taping of the star quads and the star quad layers acetylated cellulosic fibers in paper form are used.

Round the whole core a lapping of acetylated cotton with 30% combined acetic acid is applied.

Sheathing.Right on the acetylated cotton lapping a seamless tubular sheath of polyethylene tetrasulfide (trade name: Thiokol) is applied by extrusion. Then follows a layer of spirally wound tape of highly calendered ordinary cable insulating paper. At last a second seamless tubular sheath consisting of a specially blended polyvinyl-chloride (as sold under the trade names: Igelite or Protodur H) is extruded and pressed round the cable.

If desired the cable so protected may be provided with stufling, armouring and bituminous serving.

Example 3 In the third example the invention is embodied in a high voltage power cable of the three conductor masscable type.

Core of the cable-Each of the three copper or aluminium conductors of circular or any other section receives an insulation of acetylated cellulosic fibers in paper form containing 35% by weight of combined acetic acid, which is then impregnated with a suitable insulating agent (oil or mass).

Each insulated conductor is then taped with acetylated cellulosic fibers in paper form containing 35% by weight of combined acetic acid and on which a thin metallic layer has been applied by one of the well known processes for metallising paper, the tape being wound in overlapping spirals.

The gaps and interstices between the three conductors insulated as above are stuffed with paper to form a core of circular section on which a tape of metallic wires braided with cotton yarn is applied to form a screen or shield.

Because of the much lower moisture contents and the much greater absorbency of acetylated paper as compared with conventional "cable-paper= a material" saving in time can be achieved in the drying andnmpregn'ation operations.

Sheathing.'-On the screened core a layer of polymer acrylates (asfor instance"found inthe -trade"-under the In this second sheath an-int'er'medi'atedayerof calen dered cable insulating paper is taped and the whole covered with a seamless sheath applied 'by'extrusion of a specially blended poly-vinyl-chloride- (as e. 'Igelite or Protodur H).

The three conductor-cable soprotecte'dcan be further provided if required witha stufling layer, a steel tape armouring and a serving of bituminous jute tape.

Having thus disclosed the invention, what is claimed'isz' 1. An insulated cable, particularly suitable'for use as a weak-current cable, a high'voltagecabl'e and a high frequency'transmissio'n cable, saidcable Comprising a cable core consisting of at least-one insulated conductor wherein the insulation comprises acetylated cellulose fibers, the structure of whichhas been'maintained during the acetylation thereof, a multi-layered coveringof thermoplastic material for said core; and at least one layer of hygroscopic materialdisposed'between two layers of said thermoplastic covering. 7 I

2. insulated cable', particularly suitable for use as a weak currenfcablf'a high voltage cable wherein the insulation comprises acetylated cellulose fibers,- the structure of which has been maintained dur ing the acetylation thereof, a multi-layered covering of thermoplastic material for said core; at least one metallic layer disposed between said insulated core and said thermopla'sticcoveriiig, and at least one'layer of hygroscopic materialdisposed'between'two'layers of said thermoplastic covering;

3. Aninsulated cableaccordingto claim 2, wherein the said metallic layer' is in the form of a metal foil.

References Qited file of thispatent UNITED STATES PATENTS 2,029,481 Haskins Feb. 5,, 1936 2,056,085 I Alles Sept; 29, 1936 2,092,477 Scott et al Sept. 7, 1937 2,133,301 Martin' Oct. 18, 1938 2,21 ,435 Ecke1 Oct. 1, 1940 2,446,292 McConnell et a1. Aug. 3, 1948 2,577,077 Forsberg; Dec. 4, 1951 I V V anda high frequency transmission cablejsaid cable'com'prising a cable core consisting of at least one insulated conductor 

